IPD sale Volvo Parts
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy your stuff using this and it helps MVS!

V8 Balance Shaft

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo XC90s. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America).
User avatar
SuperHerman
Posts: 1123
Joined: Mon Dec 01, 2014 1:28 pm
Year and Model: 2004 & 2016 XC90
Location: Minnesota
Has thanked: 0
Been thanked: 98 times
United States of America
SuperHerman

Re: V8 Balance Shaft

Post by SuperHerman » Sun Dec 30, 2018 9:33 pm

Just want to say I don't have a V8, and most likely never will but I really appreciate all the activity and photos. No better way to learn. Keep it coming.



User avatar
Roger_850T
MVS Moderator
Posts: 236
Joined: Tue Dec 31, 2013 11:55 am
Year and Model: 854T 1995
Location: Frederick MD
Has thanked: 0
Been thanked: 9 times
United States of America
Roger_850T

Re: V8 Balance Shaft

Post by Roger_850T » Mon Dec 31, 2018 10:58 am

jimmy57, thanks for the good advice! I'll definitely watch the cams when I put it back together!

Meanwhile, I'm stuck with the cylinder head bolts. I can't get them loose. I think I need a 6' breaker and a second person. Do you have any suggestions? Thanks.

Roger


'05 XC90 V8 140k
'95 854T 310k
'02 V70 159k
'03 S80 111k (crashed)
'93 945T 217k (gone to be parted out)
'87 245 300k+ sold, still going
'84 264 Diesel, RIP at 160k
'78 242 manual everything.
'73 P1800ES, fun until the rust set in...

jimmy57
Posts: 6250
Joined: Fri Nov 12, 2010 9:25 am
Year and Model: 2004 V70R GT, et al
Location: Ponder Texas
Has thanked: 2 times
Been thanked: 149 times
jimmy57

Re: V8 Balance Shaft

Post by jimmy57 » Mon Dec 31, 2018 12:48 pm

Yes, leverage and Help is what I use.
"Help" is someone watching that socket is not going sideways. It likely may require your assistant prying the socket/extension opposite the way it wants to lean off the bolt head. NO IMPACT WRENCH, the threads are aluminum.



User avatar
SuperHerman
Posts: 1123
Joined: Mon Dec 01, 2014 1:28 pm
Year and Model: 2004 & 2016 XC90
Location: Minnesota
Has thanked: 0
Been thanked: 98 times
United States of America
SuperHerman

Re: V8 Balance Shaft

Post by SuperHerman » Mon Dec 31, 2018 12:51 pm

Are you using a 1/2" or 3/8" socket? I agree 6 point is the way to go, but how long of an extender is needed to clear the head and maintain 90 degree angle? Can you get by with a 3/8" 14mm 6 point shallow and an extender or do you think it will shear off?

On my BMW engines the crank bolt is something sick like 450 ft/lbs - the 1/2" breaker would flex like a whip so I went up to a 3/4" socket and breaker bar - attached a 6 foot garden post and it came right off. I found most of the force was going into flexing the breaker bar. On an S80 head I went with 1/2" socket and breaker bar, but it was not easy to crack them. 3/8" may just have too much flex in the system.

Looking at the pictures I see your clearance issues. Have you measured the size of the hole so you can figure out if another brand socket will fit?



User avatar
Roger_850T
MVS Moderator
Posts: 236
Joined: Tue Dec 31, 2013 11:55 am
Year and Model: 854T 1995
Location: Frederick MD
Has thanked: 0
Been thanked: 9 times
United States of America
Roger_850T

Re: V8 Balance Shaft

Post by Roger_850T » Mon Dec 31, 2018 6:58 pm

I made good progress today! Thanks for the advice about getting the head bolts loose. I now have a shiny new 3/4" socket set, plus an adapter to fit the 14mm 6-point socket that fits into the head. That, a 4' cheater bar, and a 12 year old helper to keep things steady at the right time, and I was able to break them all loose. Head is now off. Hooray! Here it is with the head off and the balance shaft cover removed.
IMG_6335.JPG
As expected, the rear bearing of the balance shaft is a shambles. Some (but not all) of the balls are missing from the bearing. I can see where water gets down the back of the bearing.
IMG_6339.JPG
IMG_6341.JPG
Next step is to make the tool for pulling the balance shaft out.

Roger


'05 XC90 V8 140k
'95 854T 310k
'02 V70 159k
'03 S80 111k (crashed)
'93 945T 217k (gone to be parted out)
'87 245 300k+ sold, still going
'84 264 Diesel, RIP at 160k
'78 242 manual everything.
'73 P1800ES, fun until the rust set in...

jimmy57
Posts: 6250
Joined: Fri Nov 12, 2010 9:25 am
Year and Model: 2004 V70R GT, et al
Location: Ponder Texas
Has thanked: 2 times
Been thanked: 149 times
jimmy57

Re: V8 Balance Shaft

Post by jimmy57 » Mon Dec 31, 2018 7:41 pm

Before you make a tool, take the three bearing retainer bolts out and push against the BS using the thermostat housing. I don't recall the force needed to get the front bearing out of block to be very much. If it is tough then three 40-45 mm long M8-1.25 bolts and a larger diameter fender washer and a 30mm long M10-1.0 bolt (check this one, this is from memory) will pull it. The washer will push against the three m8 bolt heads while pulling the shaft. The rear bearing is not a high interference fit so it knocks off easily. Put it on and leave it back a few mm. WHen you push the BS back in the rear bearing will stop against the shoulder in its saddle.



User avatar
Roger_850T
MVS Moderator
Posts: 236
Joined: Tue Dec 31, 2013 11:55 am
Year and Model: 854T 1995
Location: Frederick MD
Has thanked: 0
Been thanked: 9 times
United States of America
Roger_850T

Re: V8 Balance Shaft

Post by Roger_850T » Tue Jan 01, 2019 6:23 pm

Balance shaft is out. Hooray!

The bearing was very tight and did not want to move. It took two trips to the store and three attempts before I was able to come up with a puller that was stout enough to move it. I ended up using a piece of 3/8" steel I had around from a different project, perched atop three M8.0 1.25 40mm bolts. For reference, the bolt in the balance shaft is 10mm 1.25 pitch. Here's what I ended up with:
IMG_6352.JPG

Also, before I pulled out the balance shaft, I shot a video documenting the sound I was hearing, and what was really happening inside the engine. You can find that here:

One question I'm trying to figure out is if I lost some ball bearings or not. There were certainly gaps between the balls, suggesting some balls were missing, but then I looked at the front bearing, and it has a framework to hold the balls a fixed distance apart. If the framework is what became the metal shards I fished out, then perhaps I have all the balls. Otherwise, I have no clue where they went.

Here is the balance shaft space after I've cleaned it up a little bit.
IMG_6353.JPG
Also, for general reference, here is a nice wide angle shot of the engine bay with everything all out.
IMG_6355.JPG
I still need to get the remains of the back bearing inner race off the back of the balance shaft, but it looks like the balance shaft is in good condition and can be re-used. (Some slight surface corrosion, but no notable damage. Then, assembling a parts list and sourcing them.

Roger


'05 XC90 V8 140k
'95 854T 310k
'02 V70 159k
'03 S80 111k (crashed)
'93 945T 217k (gone to be parted out)
'87 245 300k+ sold, still going
'84 264 Diesel, RIP at 160k
'78 242 manual everything.
'73 P1800ES, fun until the rust set in...

jimmy57
Posts: 6250
Joined: Fri Nov 12, 2010 9:25 am
Year and Model: 2004 V70R GT, et al
Location: Ponder Texas
Has thanked: 2 times
Been thanked: 149 times
jimmy57

Re: V8 Balance Shaft

Post by jimmy57 » Tue Jan 01, 2019 8:51 pm

You did find the notes posted on the hole drilling after of bearing saddle and the chamferring of the sides of saddle?

Yep, I forgot the JIS threads that pop up on this engine instead of DIN/SAE metric choices that would be used on the same fasteners in Euro stuff.

I've only had one be tough to pull forward but it was a sludgy engine not nearly so nice as yours inside.
The Volvo tool for install is a drift with that m10-1.25 thread pin. You screw into onto shaft and pull bearing on and it is drilled in center for a pusher bolt on three holed triangular plate that is held by three longer M8 bolts. I might suggest a piece of pipe close to the same diameter of bearing outer race and 5/16 to 3/8 tall. The shaft doesn't stick proud of shaft much but you need dowel pin height too so maybe more than 3/8". A thick fender washer and a 25-30 mm long bolt as appropriate with center drilled enough to act as push bolt seat. Your same plate with appropriate long M8 bolts and a pusher bolt with nut on inside of plate. I don't think you can jack engine up enough to get hammer swing room for "pressing". The wisdom of hammer blows is to be questioned too. I'm not sure what info you have or how well you can make out what the tools look like in VIDA or other repair info. Not trying to step on your toes.



User avatar
Roger_850T
MVS Moderator
Posts: 236
Joined: Tue Dec 31, 2013 11:55 am
Year and Model: 854T 1995
Location: Frederick MD
Has thanked: 0
Been thanked: 9 times
United States of America
Roger_850T

Re: V8 Balance Shaft

Post by Roger_850T » Tue Jan 01, 2019 9:39 pm

jimmy57,

No stepping on toes - I'm happy for the input from someone who's done this before, thank you! I'd rather get your input upfront than screw it up and make a mistake that will ruin the engine!

Yes, I have the bulletin on the hole to drill and the side of the channel I have to file. That will come soon, after I get some parts ordered. (And manage to find some decent cutting fluid, which my local "national chain" stores don't carry...)

For pulling the shaft in, I'll probably drill some holes in the plate I have to line up with the bolts, then use a carefully selected socket (to have an OD slightly smaller than the bearing) as a drift to pull it in. I have a collection of 80mm M8x1.25 bolts that should work nicely for that, I hope.

Roger


'05 XC90 V8 140k
'95 854T 310k
'02 V70 159k
'03 S80 111k (crashed)
'93 945T 217k (gone to be parted out)
'87 245 300k+ sold, still going
'84 264 Diesel, RIP at 160k
'78 242 manual everything.
'73 P1800ES, fun until the rust set in...

User avatar
SuperHerman
Posts: 1123
Joined: Mon Dec 01, 2014 1:28 pm
Year and Model: 2004 & 2016 XC90
Location: Minnesota
Has thanked: 0
Been thanked: 98 times
United States of America
SuperHerman

Re: V8 Balance Shaft

Post by SuperHerman » Tue Jan 01, 2019 10:24 pm

Re ball bearing count - can you get an idea from the other side? If not maybe pull up the part number and dig into the design. Somewhere you will find a spec for the number of bearings. From what I read the bearing is the same one used in some Artic Cat ATVs (or another major ATV brand). When I was looking into buying a V8 I read some threads were a guy did what you are doing and he came up with some great info. Keep it coming.



Post Reply